Hydroentangled nonwoven web containing recycled synthetic fibrous materials

ABSTRACT

A hydraulically entangled nonwoven fabric that includes recycled synthetic fibers and fiber-like materials having at least one thread element composed of synthetic material with at least one irregular distortion generated by hydraulic fracture of the thread element to separate it from a bonded fibrous material while the bonded fibrous material is suspended in a liquid. This material may be used as a wiper or an absorbent material. A method of forming the material includes the steps of: (a) providing a layer of recycled synthetic fibers and fiber-like materials having at least one thread element composed of synthetic material containing at least one irregular distortion generated by hydraulic fracture of the thread element to separate it from a bonded fibrous material while the bonded fibrous material is suspended in a liquid; (b) hydraulically entangling the layer to form a nonwoven web; and (c) drying the web.

FIELD OF THE INVENTION

[0001] The present invention relates to a hydraulically entanglednonwoven fabric containing recycled fibers and a method for making anonwoven composite fabric.

BACKGROUND OF THE INVENTION

[0002] Although nonwoven webs of pulp fibers are known to be absorbent,nonwoven webs made entirely of pulp fibers may be undesirable forcertain applications such as, for example, heavy duty wipers becausethey lack strength and abrasion resistance.

[0003] Pulp fibers have been combined with staple length fibers andhydraulically entangled. However, adding staple fibers increasesexpense. In addition, suspensions containing staple fibers can be moredifficult to process utilizing conventional paper-making or wet-layingtechniques. One known technique for combining these materials is byhydraulic entangling. For example, U.S. Pat. No. 4,808,467 to Suskinddiscloses a high-strength nonwoven fabric made of a mixture of wood pulpand textile fibers entangled with a continuous filament base web.

[0004] Laminates of pulp fibers with textiles and/or nonwoven webs aredisclosed in Canadian Patent No. 841,398 to Shambelan. According to thatpatent, high pressure jet streams of water may be used to entangle anuntreated paper layer with base webs such as, for example, a continuousfilament web.

[0005] It has been proposed that bonded fibrous webs may be mechanicallybroken up into smaller pieces such as fiber bundles, threads and/orindividual fibers and these pieces then be formed into a web byhydraulic entangling. This is normally accomplished by mechanicaltearing and shredding dry material.

[0006] For example, International Application PCT/SE95/00938 states thatit is known to mechanically shred dry nonwoven and textile waste andthat dry mixed waste containing both synthetic and natural fibers may beused. According to PCT/SE95/00938, a significant feature of shreddingand tearing techniques is that the tearing or shredding operation isoften incomplete so that recycled fibers are present partly in the formof discrete bits of the original fabric that may be characterized as“flocks” or fiber bundles. These flocks are described as providingnon-uniformities that give webs containing such flocks a moretextile-like appearance.

[0007] Flocks and bits of fabric are difficult to process in subsequentoperations such as, for example, a wet-laying process, air-layingprocess, hydraulic entangling process or other web-forming processes.Presence of these non-uniformities may reduce the value of the recycledfibers as well as degrade the appearance, strength, uniformity and otherdesirable properties of a web or fabric made with the recycled fibers.Removing the non-uniformities by screening or other techniques reducesthe efficiency of the fiber recovery. Additional dry mechanicalchopping, shredding, tearing, garnetting or picking operations to reducethe fiber bundles or flocks into fibers or fiber-like material having alength of less than 5 millimeters may be impractical. In addition, theadditional mechanical work may transfer so much energy in the form ofheat that the dry material may melt into unusable clumps and maydiminish or eliminate any environmental or economic advantages initiallypresented by recycling the material.

SUMMARY OF THE INVENTION

[0008] The present invention addresses the needs discussed above byproviding a hydraulically entangled nonwoven fabric that includesrecycled synthetic fibers and fiber-like materials having at least onethread element composed of synthetic material and with at least oneirregular distortion generated by hydraulic fracture of the threadelement to separate it from a bonded fibrous material while the bondedfibrous material is suspended in a liquid.

[0009] The thread element may have a length ranging from about 1millimeter to about 15 millimeters. For example, the thread element mayhave a length ranging from about 1.5 to about 10 millimeters. As anotherexample, the thread element may have a length ranging from about 2 toabout 5 millimeters. The thread element may have a diameter of less than100 micrometers. For example, the thread element may have a diameter ofless than about 30 micrometers and, as a particular example, may have afiber diameter of from about 10 micrometers to about 20 micrometers.

[0010] According to an aspect of the invention, the irregulardistortions may be in the form of bends in the thread element, flattenedsegments of thread element, expanded segments of thread element andcombinations thereof. In addition, with recycling, the bends and/ortwists provide more effective interlocking of the fibrous web in theentangling process.

[0011] Generally speaking, the irregular distortions cause the threadelements of the recycled materials to have greater surface area thanthread elements in the bonded fibrous material prior to hydraulicfracture of the thread element to separate it from the bonded fibrousmaterial. For example, the surface areas of the recycled thread elementsare at least about 5 percent greater.

[0012] In embodiments of the invention, the recycled synthetic fibersand fiber-like materials may be a synthetic material selected frompolyesters, polyamides, polyolefins, fiberglass and combinationsthereof. In embodiments of the invention, the recycled synthetic fibersand fiber-like materials may be a synthetic thermoplastic material. Forexample, the synthetic thermoplastic material may be a polyolefin suchas polypropylene, polyethylene and combinations of the same. Thesynthetic thermoplastic material may be in the form of multicomponentfibers, filaments, strands or the like and may include fiber and/orfilaments having various cross-sectional shapes, lobes or otherconfigurations.

[0013] The hydraulically entangled nonwoven fabric may further includenon-recycled natural fibrous materials, non-recycled natural syntheticmaterials, recycled natural fibrous materials, particulate materials andcombinations thereof. For example, hydraulically entangled nonwovenfabric may further include pulp fibers. In an embodiment of theinvention, the hydraulically entangled nonwoven fabric may contain fromabout 1 to about 85 percent, by weight of recycled synthetic fibers andfiber-like materials and from about 15 to about 99 percent, by weight ofpulp.

[0014] The pulp fiber component may be woody and/or non-woody plantfiber pulp. The pulp may be a mixture of different types and/orqualities of pulp fibers.

[0015] The present invention also contemplates treating thehydraulically entangled nonwoven fabric with small amounts of materialssuch as, for example, binders, surfactants, cross-linking agents,de-bonding agents, fire retardants, hydrating agents, pigments and/ordyes. Alternatively and/or additionally, the present inventioncontemplates adding particulates such as, for example, activatedcharcoal, clays, starches, and superabsorbents to the nonwoven fabric.In one embodiment, hydraulically entangled nonwoven fabric may furtherinclude up to about 3 percent of a de-bonding agent.

[0016] The hydraulically entangled nonwoven fabric may be used as aheavy duty wiper. In one embodiment, the nonwoven fabric may be asingle-ply or multiple-ply wiper having a basis weight from about 20 toabout 200 grams per square meter (gsm). For example, the wiper may havea basis weight between about 25 to about 150 gsm or more particularly,from about 30 to about 110 gsm. The wiper desirably has a water capacitygreater than about 450 percent, an oil capacity greater than about 250percent, a water wicking rate (machine direction) greater than about 2.0cm per 15 seconds, and oil wicking rate (machine direction) greater thanabout 0.5 cm per 15 seconds.

[0017] The present invention also encompasses a method of making ahydraulically entangled nonwoven fabric that includes the steps of: (a)providing a layer of recycled synthetic fibers and fiber-like materialshaving at least one thread element composed of synthetic materialcontaining at least one irregular distortion generated by hydraulicfracture of the thread element to separate it from a bonded fibrousmaterial while the bonded fibrous material is suspended in a liquid; (b)hydraulically entangling the layers to form a nonwoven web; and (c)drying the web.

[0018] According to the present invention, the step of providing thelayer of recycled synthetic fiber and fiber-like materials may encompassdepositing a layer of the recycled fibers on a hydraulic entanglingfabric by dry forming or wet-forming techniques.

[0019] In an embodiment of the invention, the step of providing thelayer of recycled synthetic fiber and fiber-like materials may includedepositing a layer composed of recycled fibers and pulp fibers on ahydraulic entangling fabric by wet-forming techniques.

[0020] The hydraulic entangling may be carried out by conventionalhydraulic entangling techniques.

[0021] The hydraulically entangled nonwoven composite fabric may bedried utilizing a non-compressive drying process. Through-air dryingprocesses have been found to work particularly well. Other dryingprocesses which incorporate infra-red radiation, yankee dryers, steamcans, vacuum de-watering, microwaves, and ultrasonic energy may also beused.

[0022] Definitions

[0023] The term “machine direction” as used herein refers to thedirection of travel of the forming surface onto which fibers aredeposited during formation of a nonwoven web.

[0024] The term “cross-machine direction” as used herein refers to thedirection which is perpendicular to the machine direction defined above.

[0025] The term “pulp” as used herein refers to fibers from naturalsources such as woody and non-woody plants. Woody plants include, forexample, deciduous and coniferous trees. Non-woody plants include, forexample, cotton, flax, esparto grass, milkweed, straw, jute, hemp, andbagasse.

[0026] The term “average fiber length” as used herein refers to anaverage length of fibers, fiber bundles and/or fiber-like materialsdetermined by measurement utilizing microscopic techniques. A sample ofat least 20 randomly selected fibers is separated from a liquidsuspension of fibers. The fibers are set up on a microscope slideprepared to suspend the fibers in water. A tinting dye is added to thesuspended fibers to color cellulose-containing fibers so they may bedistinguished or separated from synthetic fibers. The slide is placedunder a Fisher Stereomaster II Microscope S19642/S19643 Series.Measurements of 20 fibers in the sample are made at 20× linearmagnification utilizing a 0-20 mils scale and an average length, minimumand maximum length, and a deviation or coefficient of variation arecalculated. In some cases, the average fiber length will be calculatedas a weighted average length of fibers (e.g., fibers, fiber bundles,fiber-like materials) determined by equipment such as, for example, aKajaani fiber analyzer Model No. FS-200, available from Kajaani OyElectronics, Kajaani, Finland. According to a standard test procedure, asample is treated with a macerating liquid to ensure that no fiberbundles or shives are present. Each sample is disintegrated into hotwater and diluted to an approximately 0.001% suspension. Individual testsamples are drawn in approximately 50 to 100 ml portions from the dilutesuspension when tested using the standard Kajaani fiber analysis testprocedure. The weighted average fiber length may be an arithmeticaverage, a length weighted average or a weight weighted average and maybe expressed by the following equation:$\sum\limits_{x_{i} = 0}^{k}{\left( {x_{i}*n_{i}} \right)/n}$

[0027] where k=maximum fiber length

[0028] x_(i)=fiber length

[0029] n_(i)=number of fibers having length x_(i)

[0030] n=total number of fibers measured.

[0031] One characteristic of the average fiber length data measured bythe Kajaani fiber analyzer is that it does not discriminate betweendifferent types of fibers. Thus, the average length represents anaverage based on lengths of all different types, if any, of fibers inthe sample.

[0032] As used herein, the term “spunbonded filaments” refers to smalldiameter continuous filaments which are formed by extruding a moltenthermoplastic material as filaments from a plurality of fine, usuallycircular, capillaries of a spinnerette with the diameter of the extrudedfilaments then being rapidly reduced as by, for example, eductive ormechanical drawing and/or other well-known spunbond mechanisms. Theproduction of spun-bonded nonwoven webs is illustrated in patents suchas, for example, in U.S. Pat. No. 4,340,563 to Appel et al., and U.S.Pat. No. 3,692,618 to Dorschner et al. The disclosures of these patentsare hereby incorporated by reference.

[0033] As used herein, the term “meltblown fibers” means fibers formedby extruding a molten thermoplastic material through a plurality offine, usually circular, die capillaries as molten threads or filamentsinto a high velocity gas (e.g. air) stream which attenuates thefilaments of molten thermoplastic material to reduce their diameter,which may be to microfiber diameters. Thereafter, the meltblown fibersare carried by the high velocity gas stream and are deposited on acollecting surface to form a web of randomly disbursed meltblown fibers.Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 toButin, the disclosure of which is hereby incorporated by reference.

[0034] As used herein, the term “microfibers” means small diameterfibers having an average diameter not greater than about 100 microns;for example, having a diameter of from about 0.5 microns to about 50microns, more particularly, microfibers may have an average diameter offrom about 1 micron to about 40 microns.

[0035] As used herein, the term “thermoplastic material” refers to apolymer that softens when exposed to heat and returns to generally itsun-softened state when cooled to room temperature. Natural substanceswhich exhibit this behavior are crude rubber and a number of waxes.Other exemplary thermoplastic materials include, without limitation,polyvinyl chlorides, some polyesters, polyamides, polyfluorocarbons,polyolefins, some polyurethanes, polystyrenes, polyvinyl alcohols,caprolactams, copolymers of ethylene and at least one vinyl monomer(e.g., poly(ethylene vinyl acetates), copolymers of ethylene and n-butylacrylate (e.g., ethylene n-butyl acrylates), polylactic acids,thermoplastic elastomers and acrylic resins.

[0036] As used herein, the term “non-thermoplastic material” refers toany material which does not fall within the definition of “thermoplasticmaterial” above.

BRIEF DESCRIPTION OF THE DRAWINGS

[0037]FIG. 1 is a photomicrograph of a detail of an exemplary recycledsynthetic fiber of the type used in the formation of an exemplaryhydraulically entangled nonwoven web.

[0038]FIG. 2 is a photomicrograph of a detail of an exemplary virginsynthetic staple fiber.

[0039]FIG. 3 is a photomicrograph of a detail of an exemplary recycledsynthetic fiber of the type used in the formation of an exemplaryhydraulically entangled nonwoven web.

[0040]FIG. 4 is a photomicrograph of a detail of an exemplary recycledsynthetic fiber of the type used in the formation of an exemplaryhydraulically entangled nonwoven web.

[0041]FIG. 5 is a photomicrograph of a detail of an exemplary recycledsynthetic fiber of the type used in the formation of an exemplaryhydraulically entangled nonwoven web.

[0042]FIG. 6 is a photomicrograph of a detail of an exemplary recycledsynthetic fiber of the type used in the formation of an exemplaryhydraulically entangled nonwoven web.

[0043]FIG. 7 is a photomicrograph of a detail of an exemplary virginsynthetic staple fiber.

[0044]FIG. 8 is a photomicrograph of a detail of multiple exemplaryrecycled synthetic fibers of the type used in the formation of anexemplary hydraulically entangled nonwoven web.

[0045]FIG. 9 is a photomicrograph of a detail of an exemplary recycledsynthetic fiber of the type that may be used in the formation of anexemplary hydraulically entangled nonwoven web.

[0046]FIG. 10 is a photomicrograph showing details of exemplary recycledsynthetic fibers of the type that may be used in the formation of anexemplary hydraulically entangled nonwoven web.

[0047]FIG. 11 is a photomicrograph showing details of exemplary recycledsynthetic fibers of the type that may be used in the formation of anexemplary hydraulically entangled nonwoven web.

[0048]FIG. 12 is a photomicrograph showing details of exemplary recycledsynthetic fibers of the type that may be used in the formation of anexemplary hydraulically entangled nonwoven web.

DETAILED DESCRIPTION OF THE INVENTION

[0049] The present invention encompasses a hydraulically entanglednonwoven fabric formed of recycled synthetic fibers and fiber-likematerials. The synthetic fibers and fiber-like materials are recoveredfrom bonded fibrous materials that are converted into substantiallyindividual fibers and fiber-like materials. Importantly, these bondedfibrous materials are materials that include synthetic fibers and may bebonded fibrous materials such as, for example, woven fabrics, knittedfabrics, nonwoven webs and combinations thereof. As a further example,the recycled fibers may come from nonwoven webs that are thermallybonded, adhesively bonded, mechanically entangled, solvent bonded,hydraulically entangled and/or combinations of such techniques and maycontain synthetic fibrous materials, natural fibrous materials andcombinations thereof. The synthetic fibrous material may includethermoplastic fibers and filaments.

[0050] In order to recover useable recycled synthetic fibers forhydraulic entangling, bonded fibrous webs are cut or shredded intopieces having sizes that are adapted for suspension in a liquid. Next,the pieces are suspended in liquid and mechanical work is applied to theliquid suspension of discrete pieces to generate hydraulic pressure andmechanical shear stress conditions sufficient to hydraulically fragmentthe bonded fibrous materials into fibers and fiber-like components.Finally the substantially individual fibers and fiber-like componentsare separated from the liquid.

[0051] The bonded fibrous materials may be converted into discretepieces by a conventional operation such as, for example, mechanicalshredding, mechanical cutting, mechanical tearing, mechanical grinding,pulverizing, water jet cutting, laser cutting, garnetting andcombinations thereof.

[0052] Importantly, a liquid suspension of these pieces is exposed toconditions of hydraulic pressure, shear stress, and/or cavitationalforces sufficient to fragment, rupture, rupture, burst or disintegratepieces of bonded fibrous materials into useful free fibers and fiberbundles or fiber-like materials. These process conditions used toconvert the shredded material to recycled fibers are more aggressive andstringent than those found in conventional pulping operations.

[0053] As an example, normal pulping operations typically use less thanabout 3 horsepower—day (24 hours) per dry ton of material. Embodimentsof the present invention may utilize much larger inputs of energy.According to the invention, the approximate amount of mechanical workapplied to the liquid suspension may be greater than about 3Horsepower—day (24 hours) per dry ton of bonded fibrous material—asdetermined by measuring the electric current drawn by the motorproviding movement to the components generating hydraulic pressure andshear stress conditions. This number may be greater than 4Horsepower—day per ton and may be even greater than 6 or more. Forexample, the method of the invention may be practiced utilizing 35% moreenergy; 50% percent more energy, or even more to separate useful freefibers and fiber bundles from the bonded fibrous material. It iscontemplated that, in some situations or under some conditions, theapproximate amount of mechanical work may be less than 3 Horsepower—dayper dry ton of bonded fibrous material.

[0054] Although the inventors should not be held to a particular theoryof operation, it is believed that the combination of hydraulic pressure,shear stress, and cavitational forces breaks up the material into freefibers and fiber bundles. It is also thought that the content of freefibers and the average size of the bundles can be controlled by varyingthe pressure and mechanical stress. It is generally thought that thishigh level of mechanical action or work is possible without causingsignificant degradation of the synthetic components of the bondedfibrous materials (e.g., without melting synthetic thermoplasticmaterial) because the water/liquid in the process absorbs the heatgenerated as free fibers and fiber-like materials are separated from thebonded fibrous material.

[0055] Generally speaking, conventional beating and/or refiningequipment is used to modify cellulose fibers to develop papermakingproperties of hydration and fibrillation. According to the presentinvention, conventional beaters and/or refiners may be configured oroperated in an unconventional manner to provide the hydraulic pressureand shear stress conditions sufficient to fragment and fracture thebonded fibrous material into free fibers, fiber bundles and fiber-likematerials. Exemplary beater devices are available from manufacturerssuch as Beloit Jones, E. D. Jones, Valley, and Noble & Wood.

[0056] A liquid suspension of bonded fibrous material pieces isintroduced into the beater device. Alternatively and/or additionally,bonded fibrous material pieces may be introduced directly into liquid inthe beater vat. Various proportions of bonded fibrous materials andwater may be used and one skilled in the art may determine appropriateproportions.

[0057] During operation, a cylinder or beater roll is rotated atsufficient speed so that sufficient hydraulic pressure and shear stressare produced between the blades or vanes on the roll and separate bladesmounted on a fixed plate beneath the roll.

[0058] Rotation speed, consistency of the suspension in the vat andclearance between the rotating blades or vanes and the fixed blades isalso adjusted to conditions that enhance “metal to fiber” interactionthat cuts or controls the length of free fibers, fiber bundles andfiber-like particles. The term “metal to fiber” interaction is used todescribe the contact between the bonded fibrous material and the fixedand/or rotating blades that may occur under conditions of hydraulicpressure and mechanical shear stress sufficient to sever, cut or breaklong fibers. According to the invention, this interaction should becontrolled to cut long fibers without materially affecting or loweringthe length and/or freeness of pulp or short fibers that may be presentin the suspension.

[0059] While equipment may be operated to provide fibers, fiber bundlesand fiber-like materials having a wide range of lengths, it may also beused to generate fiber and fiber-like material having an average lengthdistribution that spans approximately 7 millimeters or less. Generallyspeaking, a more uniform fiber distribution tends to enhance processingand hydraulic entangling. However, it is contemplated that a mix oflonger fibers and shorter fibers may be desirable. The longer fibers mayhave advantages in providing strength and shorter fibers may haveadvantages in providing other useful characteristics such as, forexample, absorbency, hand, drape and/or bulk.

[0060] In addition to controlling length, some “metal to fiber”interaction may generate deformations and distortions of syntheticcomponents of the bonded fibrous material. While some deformations anddistortions may be generated by hydraulic fragmentation of the bondedfibrous material others may be generated by tearing, slicing andbreaking of fiber and/or filaments. These fiber deformations andirregularities are thought to help wet forming (or dry forming) of a webas well as subsequent hydraulic entangling. These characteristics of therecycled fibers and fiber-like materials enhance their utility inhydraulic entangling processes and make it practical to producehydraulically entangled fabric that may exhibit the same or similarphysical properties as one produced from 100 percent virgin fibers andpotentially exceed those properties.

[0061] A discussion of the recycled synthetic fibers is useful tounderstanding the hydraulically entangled fabrics constructed from thesefibers. Referring now to FIGS. 1, 3-6, and 8-12, there are shown variousexemplary recycled synthetic fibers, fiber bundles and/or fiber-likematerials having at least one thread element composed of syntheticmaterial having at least one irregular distortion generated by hydraulicfracture of the thread element to separate it from a bonded fibrousmaterial while the bonded fibrous material is suspended in a liquid.

[0062] The thread element is discontinuous and, as an example, may havea length ranging from about 1 millimeter to about 15 millimeters. Forexample, the thread element may have a length ranging from about 1.5 toabout 10 millimeters. As another example, the thread element may have alength ranging from about 2 to about 5 millimeters. The thread elementmay have a diameter of less than 100 micrometers. For example, thethread element may have a diameter of less than 30 micrometers.Generally speaking, these dimensions are similar to certain varieties ofcommercially available pulps and may be readily blended with commercialpulps. In some embodiments, the thread elements may have a diameter ofless than 10 microns and may even be less than 1 micron.

[0063] The irregular distortions may be in the form of bends in thethread element, flattened segments of thread element, expanded segmentsof thread element and combinations thereof.

[0064] Generally speaking, the irregular distortions cause the threadelements of the recycled materials to have greater surface area thanthread elements in the bonded fibrous material prior to hydraulicfracture of the thread element to separate it from the bonded fibrousmaterial. For example, the surface areas of the recycled thread elementsmay be at least about 5 percent greater. The increased surface area willoften be the result of remaining fiber bond areas, cross over points,flat areas, fiber distortions and the like.

[0065]FIG. 1 is a photomicrograph (approximately 500× linearmagnification) showing a detail of an exemplary recycled syntheticfiber. The recycled fiber was recovered from a composite structurecontaining a thermally point bonded continuous polypropylene filamentweb and pulp fibers hydraulically entangled with the continuous filamentweb. The fiber visible in the center of the photomicrograph is aspunbonded polypropylene thread element having bends in the filamentsand a relatively flattened segment. At least a portion of thesedistortions, e.g. flattened sections, are generated or exposed byhydraulic fracture of the thread element from the bonded continuouspolypropylene fiber web along with the cellulose pulp (i.e., thecomposite structure). The material surrounding the thread element iscellulose pulp.

[0066]FIG. 2 is a photomicrograph (approximately 500× linearmagnification) showing conventional polypropylene staple fibersappearing in a conventional bonded carded web structure. In contrast tothe thread elements of FIG. 1, these fibers appear relatively free ofirregular distortions. The fibers have relatively smooth surfaces, evenor uniform diameters, and lack the twists, bends, kinks and otherirregular distortions that are evident in the thread element shown inFIG. 1.

[0067]FIG. 3 is a photomicrograph (approximately 120× linearmagnification) showing a detail of an exemplary recycled synthetic fiberrecovered from the same type of composite structure as the threadelement shown in FIG. 1. The fiber visible across the central region ofthe photomicrograph is a polypropylene thread element that exhibits aloop and bends as well as relatively flattened segments. At least aportion of these distortions are generated or exposed by hydraulicfracture of the thread element from the bonded fibrous material (i.e.,the composite structure). The material surrounding the thread element iscellulose pulp.

[0068]FIG. 4 is a photomicrograph (approximately 120× linearmagnification) showing a detail of an exemplary recycled synthetic fiberrecovered from the same type of composite structure as the threadelement shown in FIG. 1. The fiber visible in the center of thephotomicrograph is a polypropylene thread element. The arrow in thephotomicrograph points to a sharp bend in the thread element.

[0069]FIG. 5 is a photomicrograph (approximately 500× linearmagnification) showing a detail of an exemplary recycled synthetic fiberrecovered from the same type of composite structure as the threadelement shown in FIG. 1. The fiber visible in the center of thephotomicrograph is a polypropylene thread element that exhibits bendsand/or twists as well as a roughened segment.

[0070]FIG. 6 is a photomicrograph (approximately 500× linearmagnification) showing a detail of an exemplary recycled synthetic fiberrecovered from the same type of composite structure as the threadelement shown in FIG. 1. The fiber visible across the center of thephotomicrograph is a polypropylene thread element showing a cut end ofthe fiber that is flattened and expanded.

[0071]FIG. 7 is a photomicrograph (approximately 500× linearmagnification) showing a detail of a conventional polypropylene staplefiber. In contrast to the thread element of FIG. 6, the fiber appearsrelatively free of irregular distortions and has an end that appears tobe cut cleanly without evidence of expansion or other distortion.

[0072]FIG. 8 is a photomicrograph (approximately 250× linearmagnification) showing a detail of two exemplary recycled syntheticfibers recovered from the same type of composite structure as the threadelement shown in FIG. 1. The fibers visible across the center and nearthe lower portion of the photomicrograph are polypropylene threadelements that exhibit bends as well as roughened segments.

[0073]FIG. 9 is a photomicrograph (approximately 500× linearmagnification) showing a detail of exemplary recycled synthetic fibers.The recycled fibers were recovered from Kimtex® brand wiper containingthermally point-bonded web of polypropylene meltblown fibers. Therelatively fine meltblown fibers visible in the center of thephotomicrograph are polypropylene thread elements having bends, twists,tangles and relatively flattened segments. At least a portion of thesedistortions are generated or exposed by hydraulic fracture of the threadelements from the bonded fibrous material (i.e., the Kimtex® wiper). Thematerial surrounding the thread elements is cellulose pulp.

[0074]FIG. 10 is a photomicrograph (approximately 100× linearmagnification) showing a detail of exemplary recycled synthetic fibersrecovered from the same type of material as the thread elements shown inFIG. 9. A bond point approximately 500 micrometers in length is visiblein the center of the photomicrograph. Fibers radiate outward from theedges of the bond point in the form of polypropylene thread elementshaving bends, twists, tangles and relatively flattened segments. Atleast a portion of these distortions are generated or exposed byhydraulic fracture of the thread elements from the bonded fibrousmaterial. Some of the material in the background of the thread elementsis cellulose pulp.

[0075]FIG. 11 is a photomicrograph (approximately 500× linearmagnification) showing a detail of exemplary recycled synthetic fibersrecovered from the same type of material as the thread elements shown inFIG. 10. A larger fiber-like material or fiber bundle is approximately40 micrometers in width is visible in the center of the photomicrograph.Fibers surround and radiate outward from the edges of the fiber-likematerial or fiber bundle in the form of polypropylene thread elementshaving bends, twists, tangles and relatively flattened segments. Atleast a portion of these distortions are generated or exposed byhydraulic fracture of the thread elements from the bonded fibrousmaterial. The larger fibrous materials near the thread elements arecellulose pulp fibers.

[0076]FIG. 12 is a photomicrograph (approximately 500× linearmagnification) showing a detail of exemplary recycled synthetic fibersrecovered from the same type of material as the thread elements shown inFIG. 10. A mix of cellulose pulp and recycled fibers in the form ofpolypropylene thread elements having bends, twists, tangles andrelatively flattened segments is shown.

[0077] The hydraulically entangled web of recycled fibers and fiber-likematerials may be made by conventional hydraulic entangling techniques.For example, a dilute suspension of recycled fibers and fiber-likematerials may be supplied by a head-box and deposited via a sluice in auniform dispersion onto a forming fabric of a conventional papermakingmachine.

[0078] The suspension of fibers may be diluted to any consistency whichis typically used in conventional papermaking processes. For example,the suspension may contain from about 0.01 to about 1.5 percent byweight fibers suspended in water. Water is removed from the suspensionof fibers to form a uniform layer. The recycled fibers may also includeadded pulp fiber and/or other types of fibers, particulates or othermaterials. It is contemplated that the recycled fibers and these variousfibers and/or other material may be formed into a stratified orheterogeneous sheet or layer. Alternatively and/or additionally, thesecomponents may be blended or mixed to form a homogenous layer.

[0079] Small amounts of wet-strength resins and/or resin binders may beadded to improve strength and abrasion resistance if there is acellulose component in the fibers. Useful binders and wet-strengthresins include, for example, Kymene 557 H available from the HerculesChemical Company and Parez 631 available from American Cyanamid, Inc. Insome cases, it may be possible to add cross-linking agents and/orhydrating agents to the fibers. It is also possible to add debondingagents. One exemplary debonding agent is available from the QuakerChemical Company, Conshohocken, Pa., under the trade designation Quaker2008.

[0080] The fiber layer is then laid upon a foraminous entangling surfaceof a conventional hydraulic entangling machine. The layer of recycledfibers and fiber-like materials (and any added pulps, fibers and/orother materials) pass under one or more hydraulic entangling manifoldsand are treated with jets of fluid to entangle the recycled fibers andfiber-like materials with one another.

[0081] It is contemplated that hydraulic entangling may take place whilethe fiber layer is on the same foraminous screen (i.e., mesh fabric) onwhich the wet-laying took place.

[0082] The hydraulic entangling may be accomplished utilizingconventional hydraulic entangling equipment such as may be found in, forexample, in U.S. Pat. No. 3,485,706 to Evans, the disclosure of which ishereby incorporated by reference. The hydraulic entangling of thepresent invention may be carried out with any appropriate working fluidsuch as, for example, water. The working fluid flows through a manifoldwhich evenly distributes the fluid to a series of individual holes ororifices. These holes or orifices may be from about 0.003 to about 0.015inch in diameter. For example, the invention may be practiced utilizinga manifold produced by Honeycomb Systems Incorporated of Biddeford, Me.,containing a strip having 0.007 inch diameter orifices, 30 holes perinch, and 1 row of holes. Many other manifold configurations andcombinations may be used. For example, a single manifold may be used orseveral manifolds may be arranged in succession.

[0083] In the hydraulic entangling process, the working fluid passesthrough the orifices at a pressures ranging from about 200 to about 2000pounds per square inch gauge (psig). At about 2000 psig, it iscontemplated that the composite fabrics may be processed at speeds ofabout 1000 feet per minute (fpm). The fluid impacts the fiber layerwhich is supported by a foraminous surface which may be, for example, asingle plane mesh having a mesh size of from about 40×40 to about100×100. The foraminous surface may also be a multi-ply mesh having amesh size from about 50×50 to about 200×200. As is typical in many waterjet treatment processes, vacuum slots may be located directly beneaththe hydro-needling manifolds or beneath the foraminous entanglingsurface downstream of the entangling manifold so that excess water iswithdrawn from the hydraulically entangled material.

[0084] Although the inventors should not be held to a particular theoryof operation, it is believed that the columnar jets of working fluidwhich directly impact the relatively distorted, twisted and high surfacearea recycled fibers laying on the entangling surface work to entangleand intertwine those fibers with each other (and with other fibers thatmay be present such as, for example, pulp fibers).

[0085] Generally speaking, it is thought that the various irregularitiesof the central thread element and any branching thread elements, fibrilsor the like help the recycled fibers form a coherent entangled matrix.When recycled fibers are mixed with pulp fibers, this matrix is thoughtto help secure the pulp fibers.

[0086] After the fluid jet treatment, the hydraulically entangled fabricmay be transferred to a non-compressive drying operation. A differentialspeed pickup roll may be used to transfer the material from thehydraulic needling belt to a non-compressive drying operation.Alternatively, conventional vacuum-type pickups and transfer fabrics maybe used. If desired, the entangled fabric may be wet-creped before beingtransferred to the drying operation. Non-compressive drying of thefabric may be accomplished utilizing a conventional rotary drumthrough-air drying apparatus. The temperature of the air forced throughthe hydraulically entangled fabric by the through-dryer may range fromabout 200° to about 500° F. Other useful through-drying methods andapparatus may be found in, for example, U.S. Pat. Nos. 2,666,369 and3,821,068, the contents of which are incorporated herein by reference.

[0087] Although through-air drying processes have been found to workparticularly well, other drying processes which incorporate infra-redradiation, yankee dryers, steam cans, vacuum de-watering, microwaves,and ultrasonic energy may also be used.

[0088] It may be desirable to use finishing steps and/or post treatmentprocesses to impart selected properties to the composite fabric. Forexample, the fabric may be lightly pressed by calender rolls, creped orbrushed to provide a uniform exterior appearance and/or certain tactileproperties. Alternatively and/or additionally, chemical post-treatmentssuch as, adhesives or dyes may be added to the fabric.

[0089] In one aspect of the invention, the fabric may contain variousmaterials such as, for example, activated charcoal, clays, starches, andsuperabsorbent materials. For example, these materials may be added tothe suspension of recycled fibers used to form the fiber layer. Thesematerials may also be deposited on the fiber layer prior to the fluidjet treatments so that they become incorporated into the hydraulicallyentangled fabric by the action of the fluid jets. Alternatively and/oradditionally, these materials may be added to the hydraulicallyentangled fabric after the fluid jet treatments.

[0090] Test Methods

[0091] Trapezoidal tear strengths of samples were measured in accordancewith ASTM Standard Test D 1117-14 except that the tearing load iscalculated as an average of the first and the highest peak loads ratherthan an average of the lowest and highest peak loads.

[0092] Water and oil absorption capacities of samples were measured inaccordance with Federal Specification No. UU-T-595C on industrial andinstitutional towels and wiping papers. The absorptive capacity refersto the capacity of a material to absorb liquid over a period of time andis related to the total amount of liquid held by a material at its pointof saturation. Absorptive capacity is determined by measuring theincrease in the weight of a material sample resulting from theabsorption of a liquid. Absorptive capacity may be expressed, inpercent, as the weight of liquid absorbed divided by the weight of thesample by the following equation:

Total Absorptive Capacity=[(saturated sample weight−sampleweight)/sample weight]×100.

[0093] The basis weights of samples were determined essentially inaccordance with ASTM D-3776-9 with the following changes: 1) sample sizewas at least 20 square inches (130 cm²); and 2) a minimum of threerandom specimens were tested for each sample.

[0094] The drape stiffness of samples was measured in accordance withASTM D1388 except that the sample size is 1 inch by 8 inches.

[0095] Bulk (i.e., thickness) of a sample was measured essentially inaccordance with TAPPI 402 om-93 and T 411 om-89 utilizing a Emveco 200-ATissue Caliper Tester. The tester was equipped with a 56.42 mm diameterfoot having an area of 2500 mm². A stack of 10 samples was tested at aload of 2.00 kPa and a dwell time of 3 seconds.

[0096] Abrasion resistance testing was conducted utilizing a TaberAbraser, Model No. 5130 (rotary head, double head abrader) with ModelNo. E 140-15 specimen holder available from Teledyne Taber of NorthTonawanda, N.Y., generally in accordance with Method 5306 Federal TestMethods Standard No. 191A and ASTM Standard: D 3884 Abrasion Resistanceof Textile Fabrics. Sample size measured about 5 inches by 5 inches.Samples were subjected to abrasion cycles under a head weight of about250 grams. Each abradant head was loaded with a non-resilient,vitrified, Calibrade grinding wheel No. H-18, medium grain/medium bond.Abradant heads were vacuumed after each specimen and resurfaced aftereach sample (generally about 4 specimens). Resurfacing of abradant headswas carried out with a diamond wheel resurfacer. The abrasion testmeasured the number of cycles needed to form a ½ inch hole through thesample.

EXAMPLE

[0097] This example relates to recycling a bonded and entangledcomposite material containing natural fibers and synthetic filaments,introducing the material into the furnish stream of a wet formingprocess, depositing the material onto a nonwoven continuous filamentsubstrate and then hydraulically entangling the materials together.

[0098] A composite hydraulically entangled material containing virginwood pulp and a continuous web of bonded synthetic polypropylenefilaments (approximately 20 percent, by weight) (i.e., a spunbondcontinuous filament web)—available from the Kimberly-Clark Corporation,Roswell, Ga. under the trademarks WYPALL® WORKHORSE® manufactured ragsand HYDROKNIT® fast absorbing materials—was shredded into pieces rangingfrom about 10-350 mm in length and 3-70 mm in width. The compositecontained approximately 80% by weight pulp and about 20 percent, byweight, polypropylene filaments. The material was shredded utilizing ashredder available from the East Chicago Machine Tool Company. Thepieces were transferred to a conventional Hollander-type industrialbeater manufactured by E. D. Jones & Sons, Pittsfield, Mass. The beaterwas a “Number 3 Jones Beating Unit” equipped with a 45 degree diagonalbed plate. The beater had a rotating roll with blades or vanes generallyaligned on the roll. The blades or vanes were approximately ¼ inch (˜6mm) wide, approximately ½ inch (˜12 to 13 mm) high. These were spacedapproximately ½ inch (˜12 to 13 mm) apart on the exterior of the rollperpendicular to the direction or plane of rotation. A fixed plate wasmounted just below the rotating roll and was equipped with blades or“knives” that were approximately ⅛ inch (˜3 mm) wide, ¼ inch (˜6 mm)high, spaced approximately ⅜ inches (˜9 to 10 mm) apart. These werealigned at an angle of 45 degrees to the direction or plane of rotation.

[0099] The rotating roll had a diameter of 72 inches, a width of 72inches, 192 blades each having a length of 72 inches and spaced one-halfinch apart. The roll weighed approximately 16 tons. Generally speaking,the speed of rotation is constant and the variable that is modified isthe pressure or load on the roll. The roll was mounted such that a gaugepressure reading of 0 psi corresponded to very little or no portion ofthe weight of the roll (˜0 tons) counteracting the force generated byfibers and pieces of bonded fibrous material as they squeezed as theypassed through the gap existing between the blades at the bottom of therotating roll and the fixed blades mounted underneath the roll. A gaugepressure reading of 50 psi corresponded to approximately one-half of theweight of the roll (˜8 tons) counteracting the pressure generated fibersand pieces of bonded fibrous material as they squeezed through the gapexisting between the blades at the bottom of the rotating roll and thefixed blades mounted underneath the roll. A gauge pressure reading of100 psi corresponded to approximately the full weight of the roll (˜16tons) counteracting the pressure generated by fibers and pieces ofbonded fibrous material as they squeezed through the gap existingbetween the blades at the bottom of the rotating roll and the fixedblades mounted underneath the roll.

[0100] Water was added to the shredded material and hydraulic pressureand shear stress was applied to the material in the Hollander-typebeater in two stages. Hydraulic pressure and shear stress was controlledby adjusting the load on the roll as it rotated. In this particulararrangement, hydraulic pressure and shear stress is generated by a“paddle wheel” type pumping action produced when the beater roll rotatesand its attached blades or vanes force liquid and wet material against afixed plate with blades mounted diagonally to the direction or plane ofrotation. Generally speaking, a greater load applied to the rotatingroll produces less clearance between the rotating roll and the fixedplate. This corresponds to greater levels of hydraulic pressure andshear stress.

[0101] During the first stage, the pressure or load against the rotatingroll was 0 pounds per square inch gauge (psig) for 10 minutes.Essentially, no load was applied and the “paddle wheel” action of therotating roll squeezed the pieces in the suspension through a gap ofabout 1 cm or more between blades of the rotating roll and bladesmounted on the fixed plate. Generally speaking, the first stage was usedto wet the shredded material and separate the natural fibers from thesynthetic fibers. The consistency was adjusted to be about 3.3 percent(the percentage by weight of air or oven dry fibrous material in thesuspension).

[0102] During the second stage, conditions were adjusted to establishsmall zones of very high hydraulic pressure, shear stress, and possiblycavitation forces between the moving blades on the rotating roll andfixed blades near or at their closest point of contact. These smallzones are thought to generate a micro-bursting action on the shreddedbonded fibrous material to hydraulically fragment and/or blow apart andreduce the resulting synthetic fiber length. In addition, the hydraulicfragmentation and “metal to fiber” or “metal to bonded fibrous material”contact controls the length of the longer synthetic filaments. In thisexample, the specific objective was to control the length of thesynthetic fibers so the length is maximized while still producing asheet with uniform appearance and physical properties and withoutmaterially lowering the length or freeness of pulp fibers that may bepresent in the suspension.

[0103] In the second stage, pressure on the gauge for the rotating rollwas increased to 50 psig and the clearance between the blades of therotating roll and the fixed plates decreased to between 1 and 10 mm andapproximately one-half of the weight of the 16 ton roll (˜8 tons) wasavailable to counteract the pressure generated by fibrous pieces as theywere squeezed through the gap between the roll and the fixed plate.These conditions were maintained for 50 minutes.

[0104] After treatment, samples of the free fibers, fiber bundles andfiber-like materials were examined microscopically. Natural or pulpfibers were separated and measured separately from the synthetic fibers.In this example, average fiber length was determined as previouslydescribed—by manually separating a random sample of 20 synthetic fibersand 20 pulp fibers, measuring the length of individual fibers utilizinga microscope, and then calculating an average length. The resultingrecycled fibers and fiber-like materials had the followingcharacteristics:

[0105] The average length of the synthetic fiber was approximately thesame length as the wood pulp fibers. Average length of the syntheticfibers was 4.21 mm. The length of individual fibers in the sample rangedfrom 2.54 to 7.11 mm. It should be noted that, prior to processing, thesynthetic fibers initially were substantially continuous polypropylenefilaments having indeterminate lengths or lengths at least far exceeding7.11 mm. The average fiber length for the pulp component was 2.7 mm. Thelength of individual pulp fibers in the sample ranged from 1.52 to 3.94mm.

[0106] The wood pulp fiber freeness shows a slight reduction (about 10%)indicating that some additional surface area was developed on the woodpulp fiber component of the composite. However the fiber length was notaffected.

[0107] Substantial numbers of synthetic fibers have increased surfacearea as a result of the remaining individual fiber bond areas, crossovers, and flat areas.

[0108] The treated recycled fiber stream (containing wood pulp fibersand synthetic fibers) were introduced into the furnish stream of a wetforming process. The recycled fibers were blended inline with virginradiata pine pulp fibers (Laja 10 available from CMPC Celulosa of Chile)at a level of 20% by dry weight.

[0109] This blend of fibers was formed into a wet sheet having a basisweight of 50 grams per square meter (gsm) utilizing a forming wireavailable from Albany International under the designation 84M. The wetsheet was then laid on top of a layer of continuous filamentpolypropylene spunbond having a basis weight of approximately 24 gsm.The two layers were supported on an hydroentangling wire available fromAlbany International under the designation 90 BH. The layers wereentangled utilizing five manifolds. Each manifold was equipped with ajet strip having one row of 0.005 inch holes at a density of 40 holesper inch. The water pressure was 1100 pounds per square inch gauge andthe total time the web was exposed to pressure was 213 microseconds.

[0110] The resulting composite sheet was then dried to a final product.The resulting product was compared to a control hydroentangled materialmade with the same wood pulp and spunbond in the same ratios and underthe same conditions but without the recycled fibers. These results areshown in Table 1 below: TABLE 1 Product Without Product With Recycled20% Recycled PROPERTIES Material Material Basis Wt 65.7 gsm 66.0 gsmThickness 12.88 mils 12.64 mils CD Trap Tear  1068 grams  1070 grams MDTrap Tear  1805 grams  1868 grams CD Drape 3.75 cm 4.21 cm MD Drape 6.11cm. 6.09 cm Pulp Side Abrasion 13.2 cycles 12.7 cycles Water Capacity 18.4 grams 19.77 grams

[0111] A second run was carried out utilizing the same materials andconditions except that pressure used to hydraulically entangle thesample containing the 20% recycled material was increased to 1200 psig.The material was dried in the same manner as before. The resultingproperties are shown below in Table 2: TABLE 2 Product Without ProductWith Recycled 20% Recycled PROPERTIES Material Material Basis Wt 65.7gsm 63.5.0 gsm Thickness 12.88 mils 12.7 mils CD Trap Tear  1068 grams 1179 grams MD Trap Tear  1805 grams  2147 grams CD Drape 3.75 cm 4.31cm MD Drape 6.11 cm. 6.16 cm Pulp Side 13.2 cycles 17.3 cycles AbrasionWater  18.4 grams 19.10 grams Capacity

[0112] It is evident from Table 2 that higher entangling pressures maybe used with the recycled fibers. While these samples were entangledutilizing a carrier fabric or substrate (i.e., the spunbond webs), it isbelieved the Examples demonstrate that recycled fibers may be entangledwithout such a carrier fabric or substrate and directly on ahydroentangling wire.

[0113] The recycled fibers that have been hydraulically fragmentedprovide advantages because they are generally uniform and can be readilyhydraulically entangled into a tough, coherent fabric without the flocksand non-uniformities of previous recycled materials formed from bondedfibrous webs. The relatively distorted, twisted and irregular nature ofthe recycled materials used in the present invention is thought toresult in greater efficiency because less material is washed out by thehigh pressure jets. This is believed to be due, at least in part, to thehigher surface area and fiber morphology causing less fiber loss. Thestructure of the recycled fibers and fiber-like materials offeradditional advantages because they are readily adapted to wet-formingprocesses and have good retention in the forming section. Furthermore,the relative ease with which these recycled fibers can be processed bywet-forming techniques provides a suitably uniform starting material forhydraulic entangling.

[0114] A highly uniform fabric offers advantages. A fabric that ishighly uniform in appearance tends to be aesthetically pleasing. Lesspulp material and/or lighter basis weight substrates may be used withoutsacrificing the material's ability to mask or cover. In some cases,certain tensile properties and other physical characteristics may beless likely to have strong variations or localized spots ofnon-uniformity.

[0115] While the present invention has been described in connection withcertain preferred embodiments, it is to be understood that the subjectmatter encompassed by way of the present invention is not to be limitedto those specific embodiments. On the contrary, it is intended for thesubject matter of the invention to include all alternatives,modifications and equivalents as can be included within the spirit andscope of the following claims.

What is claimed is:
 1. A hydraulically entangled nonwoven fabriccomprising: recycled synthetic fibers and fiber-like materialscomprising at least one thread element composed of synthetic materialhaving at least one irregular distortion generated by hydraulic fractureof the thread element to separate it from a bonded fibrous materialwhile the bonded fibrous material is suspended in a liquid.
 2. Thehydraulically entangled nonwoven fabric of claim 1, wherein the threadelement has a length ranging from about 1 millimeter to about 15millimeters.
 3. The hydraulically entangled nonwoven fabric of claim 2,wherein the thread element has a length ranging from about 1.5 to about10 millimeters.
 4. The hydraulically entangled nonwoven fabric of claim3, wherein the thread element has a length ranging from about 2 to about5 millimeters.
 5. The hydraulically entangled nonwoven fabric of claim1, wherein the irregular distortions are in the form of bends in thethread element, flattened segments of thread element, expanded segmentsof thread element and combinations thereof.
 6. The hydraulicallyentangled nonwoven fabric of claim 1, wherein the thread elements of therecycled materials have surface areas that are greater than comparablethread elements in the bonded fibrous material prior to hydraulicfracture of the thread element to separate it from the bonded fibrousmaterial.
 7. The hydraulically entangled nonwoven fabric of claim 6,wherein the surface areas of the recycled thread elements are at leastabout 5 percent greater than comparable thread elements in the bondedfibrous material prior to hydraulic fracture of the thread element toseparate it from the bonded fibrous material.
 8. The hydraulicallyentangled nonwoven fabric of claim 1, wherein the synthetic material isa synthetic thermoplastic material.
 9. The hydraulically entanglednonwoven fabric of claim 1, further comprising pulp fibers.
 10. Thehydraulically entangled nonwoven fabric of claim 9 comprising from about1 to about 85 percent, by weight of recycled synthetic fibers andfiber-like materials and from about 15 to about 99 percent, by weight ofpulp.
 11. The hydraulically entangled nonwoven fabric of claim 1 havinga basis weight of from about 20 to about 200 grams per square meter. 12.The hydraulically entangled nonwoven fabric of claim 1, wherein therecycled synthetic fibers and fiber-like materials are selected frompolyesters, polyamides, polyolefins and combinations thereof.
 13. Thehydraulically entangled nonwoven fabric of claim 1, wherein the pulpfibers are selected from the group consisting of virgin hardwood pulpfibers, virgin softwood pulp fiber, secondary fibers, and mixtures ofthe same.
 14. The hydraulically entangled nonwoven fabric of claim 1,further comprising clays, starches, particulates, and superabsorbentparticulates.
 15. The hydraulically entangled nonwoven fabric of claim1, further comprising up to about 3 percent of a de-bonding agent.
 16. Awiper comprising one or more layers of the hydraulically entanglednonwoven fabric of claim 1, said wiper having a basis weight from about20 gsm to about 200 gsm.
 17. The wiper according to claim 16 having abasis weight from about 40 to about 150 gsm.
 18. A method of making ahydraulically entangled nonwoven fabric, the method comprising:providing a layer of recycled synthetic fibers and fiber-like materialscomprising at least one thread element composed of synthetic materialhaving at least one irregular distortion generated by hydraulic fractureof the thread element to separate it from a bonded fibrous materialwhile the bonded fibrous material is suspended in a liquid;hydraulically entangling the layer to form a nonwoven web; and dryingthe web.
 19. The method of claim 18 wherein the step of providing thelayer of recycled synthetic fiber and fiber-like materials comprisesdepositing a layer of the recycled fibers on a hydraulic entanglingfabric by dry forming or wet-forming techniques.
 20. The method of claim18 wherein the step of providing the layer of recycled synthetic fiberand fiber-like materials comprises depositing a layer composed ofrecycled fibers and pulp fibers on a hydraulic entangling fabric bywet-forming techniques.